Method and apparatus for laying and interconnecting cables in a raised floor system

ABSTRACT

An assembly of floor panels adapted to be laid adjacent to one another to form a floor is disclosed, wherein at least one of the assembly of floor panels comprises an exposed floor surface and a covered surface, an opening through said floor and covered surfaces, and a junction box that is attached to the covered surface and enclosing the opening. Further, a receptacle is adapted to be mounted to the junction box, and a cover is mounted to be disposed from a first position that permits at least one utility cable to be placed through the opening and coupled to the receptacle, to a second position preventing the one utility cable from being placed through the opening.

FIELD OF THE INVENTION

[0001] The invention relates in general to electrical distribution systems for buildings and in particular to such systems for use beneath floor commonly referred to as raised floor, access floor, false floor, computer floor, and the like.

[0002] More specifically the invention relates to a box to be connected to the underside of a raised floor panel and to the electrical system below the floor to provide power and communication services at a work station on the floor

BACKGROUND OF THE INVENTION

[0003] One of the principal objectives of the invention is to improve the useful art of electrical distribution systems for raised floors by providing an improved floor box: which provides for the use of flexible wiring systems with raised floors; which can provide for power, telephone, and data services at one location or any combination of same; which permits through power, which can be raised out with its floor panel and quickly disconnected from the distribution system; and which can be fabricated from stamped parts and, thus, contribute to low cost.

SUMMARY OF THE INVENTION

[0004] This invention comprises an assembly of floor panels adapted to be laid adjacent to one another to form a floor. At least one of the assembly of floor panels comprises an exposed floor surface and a covered surface, an opening through the floor and covered surfaces, and a junction box attached to the covered surface and enclosing the opening. A receptacle is mounted to the junction box. Further, a cover is mounted to be disposed from a first position that permits at least one utility cable to be placed through the opening and coupled to the receptacle, to a second position preventing the one utility cable from being placed through the opening.

[0005] In a further aspect of this invention, the receptacle is mounted to the junction box to be connected to at least one second utility cable at a point outside of the junction box.

[0006] In another aspect of this invention, the floor panel includes a second cover mounted on the floor surface to be disposed from a first position covering the opening to a second position uncovering the opening.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]FIGS. 1A and B illustrate a raised floor system in accordance with the teachings of this invention, wherein a wide variety of cables may be laid in that space defined between a previous floor and a raised floor;

[0008]FIGS. 2A, B and C show respectively a first cross sectional view taken along line I-I of FIG. 2C, a second cross sectional view taken along line II-II of FIG. 2C and a perspective view of the combination of one of the floor panels that comprise the raised floor as shown in FIGS. 1A and B and a junction box secured to its floor panel;

[0009]FIGS. 3A and B show respectively perspective views of another illustrative embodiment of an openable cover that includes a cable passing member which is disposable in a closed positioned in a closed position as shown in FIG. 3A and in an open position as shown in FIG. 3B; and

[0010]FIG. 4 is a functional block diagram showing how the junction boxes are disposed at selected points throughout the raised floor system and are interconnected with each other in an efficient manner such that power is supplied to each junction box and data is received from and/or to each of the boxes.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THIS INVENTION

[0011] Referring now to the drawings and, in particular to FIG. 1, there is shown a raised floor system 10 in accordance with the teachings of this invention that comprises a plurality of floor panels 12, which are of a common configuration and size. In particular, the panels 12 of FIG. 1A are of a rectangular configuration, and those of FIG. 1B of a square configuration. The floor panels 12 are raised from and supported above a previous floor (not shown) by a plurality of panel support modules 16, which are laid out as shown in FIGS. 1A and B. Each panel support module 16 comprises a plurality of pedestals 18, which are disposed in rows and columns of a rectilinear grid whereby paths for cables 26 are formed along the columns and the rows, and along the diagonals of the grids of the panel support modules 16. In an illustrative embodiment of this invention, the cables 26 are assembled into a plurality of bundles 24, which are then laid into the paths formed by the columns, rows and diagonals of the pedestals' grids. Each of the bundles 24 of the cables 26 are assembled together by ties 27. For example, cables 26 a-1 , 26 a-2 and 26 a-3 are assembled and are tied together by the tie 27 to form the bundle 24 a.

[0012] After the panel support modules 16 have been laid out as shown in FIG. 1A on the previous floor, the floor panels 12 are laid on a plurality of the tops 19 of the pedestals 18, appreciating that each pedestal 18 has a top 19 spaced from its base member 20 and that each module 16 has a plurality of pedestals 18 arranged thereon in the grid configuration. In addition, the top 19 of each pedestal 18 has a pair of grooves 22 a and b disposed therein to intersect each other perpendicularly. As shown in FIGS. 2A and 2B, each of the plurality of floor panels 12 has a plurality of lips 14 a, b, c and d disposed respectively along its four edges, whereby each lip 14 of a floor panel 12 is disposed and held in an aligned set of the groves 22 a or b. After the plurality of floor panels 12 are so mounted, the corresponding top surfaces 13 of the laid panels 12 form the desired raised floor surface. This arrangement provides not only a raised floor surface, which may be used as any other floor, but also provides any number of cables to run through the space between the previous floor and the raised floor.

[0013] As particularly shown in FIG. 1B, that in addition to the floor panels 12′ that only present their floor surfaces, there are also, for example, shown a plurality of floor panels 12″a, b, c and d, each of which are constructed to include a terminal junction box 30, whereby selected of the cables 26 may brought to and interconnected with a receptacle 52 at a selected point anywhere in the floor surface as will now be more fully explained with respect to FIGS. 1B, 2A, B and C. Each junction box 30 is mounted within an opening 15 through its corresponding floor panel 12″, and includes a plurality of side walls 32 a, b, c and d which may illustratively formed of a single metal sheet. It is further contemplated, that the junction box could employ removable sides that may be replaced with sides containing receptacle knockouts of many different sizes for accommodating receptacles of different sizes and ability to handle different types of signal. As illustrated best in FIG. 2A, the opposing side walls 32 a and c have corresponding bottom tabs 34 a and b, which are bent at right angles with their side walls 32 a and c and are secured to a bottom 38 by metal screws (not shown), for example. As best shown in FIG. 1B, the junction box 30 has at its top side, plurality of top tabs 36 a, b, c and d extending respectively from corresponding sides 32 a, b, c and d of the box 30. In turn, each top tab 36 is secured to the top surface of its floor panel 12″ by fasteners 17, which may illustratively take the form of metal screws.

[0014] The side walls 32 include a variety of receptacle knockouts 50, which may be selectively removed to provide an opening 48 for receiving a receptacle 52 of a corresponding configuration to facilitate the mounting of the receptacle 52 therein. As would be appreciated by one skilled in the art, the junction box 30 of this invention is adapted to receive and mount receptacles 48 of different sizes and configurations, and to carry different types of signals including light and electrical, i.e., power, telephone, video, digital data, wireless via an antenna, etc. Review of FIGS. 2A, B and C indicates that there are receptacle openings 48 of varying size and configuration dependent on the receptacles 52 to be mounted therein. In FIG. 2A, there are shown receptacle knockouts 50 a, b, c, d, e and f which remain in tact, while the knockouts 50 c and f have been removed to permit the respective mounting of the receptacles 52 a-1 and a-2 therein; receptacles 52 a are particularly adapted to carry telephone signals. Similarly in FIG. 2B, the side wall 32 b has a receptacle knockout 50 g formed therein; knockout 50 g is been removed to form an opening 48 for receiving a power receptacle assembly 86 b, which in turn comprises power receptacles 52 b-1 and b-1. In FIG. 2C, the side wall 32 a is shown with receptacles 52 b-3 and b-4 mounted within corresponding openings 48. Further, the side wall 32 d, as shown in FIG. 2C, has a relatively large receptacle knockout, which is adapted to mount a power receptacle assembly 86 d, which comprises one or more power receptacle 52 b.

[0015] Data is brought to and from each of the data receptacles 52 a by internal data cables 26 a as best shown in FIG. 2B. In particular, the data cables 26 a are fed to data terminal boxes 76 c, which in turn are connected to the data receptacles 52 a-1 and a-2 as shown in FIG. 2A. Further, power is brought to the power receptacles 52 by internal power cables 26 b. In particular, a power cable 26 b is connected to a power terminal box 74 a, as shown in FIG. 2B. The terminal box 74 a illustratively includes a pair of female power receptacles 78 a and b, each receptacle having a plurality of female terminals 90. Each power cable 26 b is connected to a receptacle 78 by a male power receptacle. 80 a, which comprises a plurality of male terminals 88. Power is supplied from the cable 26 b via the pins 88 mated with the female terminals 90 and interconnections 92 to selected of the receptacles 52 b. As would be appreciated by one skilled in the art, the power receptacle assembly 86 may include a circuit board which is wired to connect power to selected of the power receptacles 52 b and is replaceable to energize different receptacles 52 b. Further, one power cable 26 b supplies power to the female power receptacle 78 a of one junction box 30, while power is outputted from the another female power receptacle 78 b to another junction box 30, as will be explained below in detail.

[0016] Still referring to FIGS. 2A, B and C, each floor plate 12″ includes a frame 40 which is disposed about the opening 15 that permits access into the interior of the terminal junction box 30 and which serves to pivotally mount an openable cover 40. In particular, a pin 42 extends through a left handed portion of the cover 40, as shown in FIG. 2A, and permits the cover to be rotated as shown by an arrow 56 between a position closing the cover 40 as shown in FIG. 2A and an open position as shown in FIG. 2B.

[0017] Referring now to FIGS. 3A and B, there is shown a cable passing lid and handle 58 which selectively closes or opens access to the interior of the junction box 30 and, in particular, the receptacles 52 therein (FIGS. 2A and B). In addition, the lid/handle 58 functions as a handle to permit a user to manually grasp the lid/handle 58 to open the cover 40 as shown in FIG. 2C or to close the cover 40 as shown in FIGS. 3A and B. A slot 60 is cut or otherwise formed within the cover 40 for receiving and securing a frame 62 therein. The frame 62 permits the lid/handle 58 to pivot by use of a pin (not shown) that is disposed through a rear portion (as seen in FIGS. 3A and B) of the lid/handle 58. In particular, the lid/handle 58 pivots between a first position as shown in FIG. 3A wherein a top lid surface 64 of the lid/handle 58 is substantially flush with the surface of the cover 40 and with the top surface 13 of the floor panels 12, and further, blocks access to the interior of the junction box 30, and a second position as shown in FIG. 3B, wherein access is established to the interior of the junction box 30. In the first position, the lid/handle 58 is disposed out of the way so that users may walk on the floor without tripping on or damaging the external cables 72 or their receptacles or plugs. In the second position of the lid/handle 58, an external cable 72 may be inserted through one of a pair of passages 70 a and b, and into the interior of the junction box 30, whereby a male connector (not shown) is mated with one of the female receptacles 52 a or b, as are disposed within the junction box 30. In particular, the lid/handle 58 comprises the top member 64, a bottom member 67, a pair of side members 66 disposed on either side of the members 64 and 67, and a divider 68 for forming the pair of passages 70 a and b. More than one external cable 72 may be inserted through the passages 70; it is contemplated that each of the external cables 72 may be used to carry a particular type of signal, e.g., an electrical or light, and carry power or various types of information (or data) or power.

[0018] Referring now to FIGS. 1A, 2B and 4, there will now be explained a method of laying out an initial network of internal cables 26 in the raised flooring system 10 described above, and to reroute the layout of the initial network to provide (or remove) signals, e.g., in the form of light or electricity, to a particular point on the floor created by the system 10. In an illustrative embodiment of this method where it is desired to supply signals to that point in the floor where a floor panel 12′a, now resides as shown in FIG. 4. First, a panel 12″ with a junction box attached thereto as described in detail with respect to FIGS. 1B, 2A, 2B and 2C is brought to that point and is disposed in the flooring system in place of the floor panel 12′. Then, a cable 26 is connected to a terminal box. If the cable is a data cable 26 a, it is connected to a female power receptacle 78. If the cable is a power cable 26 b, it is connected to a female power receptacle 78. It is appreciated that the power may be derived from one of the adjacent junction box and panel combinations or may be derived directly from main power. This method is flexible and time saving in that a new junction box 30 may quickly be disposed at any point over the array floor panels 12′ and 12″. In particular, there is no need to replace the entire floor or a significant part of the existing floor. Illustratively, only a single floor panel needs to be replaced. In a further aspect of this invention, the circuit which may be incorporated within the power receptacle assembly 86 may be replaced with another, whereby the voltage, current and/or power that is supplied to this point may be controlled in view of the needs of the equipment to be dispose at this point in the floor system. The savings in labor costs for wiring a new layout, as well as the flooring materials, are significant. The construction of a new layout or the change of an existing layout in accordance with the teaching s of this invention may be accomplished substantially faster than prior art floor systems. 

1. In an assembly of floor panels adapted to be laid adjacent to one another to form a floor, at least one of the assembly of floor panels comprising: a) an exposed floor surface and a covered surface; b) an opening through said floor and covered surfaces; c) a junction box attached to said covered surface and enclosing said opening; d) a receptacle adapted to be mounted to said junction box; and e) a cover mounted to be disposed from a first position that permits at least one utility cable to be placed through said opening and coupled to the receptacle, to a second position preventing the one utility cable from being placed through said opening.
 2. The floor panel as claimed in claim 1, wherein said receptacle is mounted to said junction box to be connected to at least one second utility cable at a point outside of said junction box.
 3. The floor panel as claimed in claim 1, wherein there is a second cover mounted on said floor surface to be disposed from a first position covering said opening to a second position uncovering said opening.
 4. The floor panel as claimed in claim 3, wherein said first mentioned cover is mounted on said second cover.
 5. The floor panel as claimed in claim 4, wherein said first cover takes the form of a lid that includes a handle that can be manually grasped to dispose said first cover from its first to its second position.
 6. The floor panel as claimed in claim 1, wherein said cover covers said opening in said second position. 